Form for portable concrete building module

ABSTRACT

The form is used for casting wall portions of a single rectangular room as a modular unit to be assembled with other such units and floor and ceiling structure to build homes, apartment houses and other buildings. The form comprises a core form and two exterior forms. The core form is contractible in all directions for stripping. The two exterior forms are L-shaped, each embracing one end wall and one side wall of the room, these forms being supported by trolleys on diagonal tracks for movement away from each other in stripping.

Unlted States Patent 1191 1111 3,811,646 Beasley May 21, 1974 FORM FORPORTABLE CONCRETE 2,495,100 l/1950 Henderson 425/446 BUILDING MODULE2,616,146 11/1952 Haase 249/179 X 2,807,071 9/1957 Francis et al.249/181 Inventor! Robert y, Tualatm, eg- 2,903,777 9/1959 Mitchell249/167 x 2,916,795 12/1959 Henderson.... 249/50 X [73] Assgnee' TedNels Company Portland 3,168,771 2/1965 Nelson 249/161 x 016% 3,276,093/1966 Swayze et al. 425 424 [22] Filed: Nov. 17, 1972 PrimaryExaminer-J. Howard Fllnt, Jr. APPL N04 307,621 Attorney, Agent, orFirm-Lee R. Schermerl'lorn Related U.S. Application Data [60]Continuation of Ser. No. 150,147, June 4, 1971, [57] ABSIIRACTabandoned, which i a division or 5 No, 731,55 The form ls used forcastlng wall portlons of a slngle Dec. 5. 1968, Pat. No. 3,614,054.rectangular room as a modular unit to be assembled with other such unitsand floor and ceiling structure to [52] U.S. Cl 249/144, 249/167,249/161, build homes, apartment houses and other buildings. 249/180,249/ 184, 425/450, 249/ 179 The form comprises a core form and twoexterior [51] Int. Cl B28b 7/30 forms. The core form is contractible inall directions [58] Field of Search 249/144, 50, 161, 179, forstripping. The two exterior forms are L-shaped, 249/153, 181, 167;425/446, 424 each embracing one end wall and one side wall of the room,these forms being supported by trolleys on diag- [56] References Citedonal tracks for movement away from each other in UNITED STATES PATENTSStripping 2,219,106 10/1940 Kruckenberg 249/153 6 Claims, 7 DrawingFigures F JLJ J1 ":11 1 1 115,

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j i m ROB ERT. W. BEASLEY PMEWEWY 2 I ran SHEET 2 B? 3 INVENTOR. ROBERTW. BEASLEY Mi 0r 'ATENTEDMM 21 19?:

SHEET 3 BF 3 INVENTOR. ROBERT W. BEASLEY 3Y3 f FORM FOR PORTABLECONCRETE BUILDING MODULE CROSS REFERENCES TO RELATED APPLICATIONS Thisis a continuation of application Ser. No. 150,147, filed June 4, 1971,now abandoned, which in turn is a division of Ser. No. 781,554, filedDec. 5, 1968, now US Pat. No. 3,614,054.

BACKGROUND OF THE INVENTION This invention relates to an improved formfor portable concrete building modules and the like and has particularreference to a form for casting the wall portions of a singlerectangular room as a modular unit to be assembled with other such unitsand floor and ceiling structures in a building construction.

According to conventional practice, buildings having a wood or steelframe are constructed piece by piece, first erecting the frame and theninstalling floors and walls piece by piece on the frame. In concreteconstruction. the necessary forms are built up progressively as theconcrete is poured. Substantially all of the construction work is donein the field, making the operation slow and costly. Attempts have beenmade to prefabricate certain parts and this reduces the field work tosome extent but does not essentially change the ageold methods ofconstruction.

Objects of the present invention are, therefore, to provide a form forportable concrete building modules so that a building may be constructedessentially by merely assembling large prefabricated units in the mannerof building blocks, to provide a form for casting the wall portions ofan entire room as a single portable unit and to provide a form for abuilding module having a collapsible core and rollaway exterior formparts.

SUMMARY OF THE INVENTION The present form comprises a contractible coreform and two exterior L-shaped forms for casting the wall portions of arectangular room as a single portable unit. The core form has acontinuous peripheral skin. A vertically movable frame within the coreform pulls the central portion of each side inwardly. As the four sidesare caused to bow inwardly, the corner portions also contract inwardlythereby effecting the stripping of the core form. The L-shaped exteriorforms are rigid and mounted on trolleys to roll away from each other ina diagonal direction for stripping. The cast module may then be liftedout vertically. The principles of the invention may also be applied toforms for modules which are not rectangular.

The invention will be better understood and additional objects andadvantages will become apparent from the following description of thepreferred embodiment illustrated in the accompanying drawings. Variouschanges may be made in the details of construction and arrangement ofparts and certain features may be used without others. All suchmodifications are included in the invention.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a plan view with partsbroken away, showing a form for portable concrete building modulesembodying the principles of the invention;

FIG. 2 is a sectional view on the line 2-2 in FIG. 1;

FIG.3 is a sectional view on the line 33 in FIG. 1;

FIG. 4 is an enlarged sectional view on the line 44 in FIG. 1;

FIG. 5 is a fragmentary enlarged view showing a-detail in FIG. 3;

FIG. 6 is a fragmentary enlarged sectional view showing a detail in FIG.11; and

FIG. 7 is a diagrammatic top plan view showing the stripping of theforms.

DESCRIPTION OF THE PREFERRED EMBODIMENT The invention will be betterunderstood by referring first to FIG. 7 showing the stripping of theforms from the concrete module M. Core form C comprises a continuousflexible peripheral skin having .four sides to form the walls of arectangular room. The central portion of each side has been pulledinwardly as indicated by the arrows 10. As the sides bow inwardly, theadjacent corners are moved closer together causing the corners to moveinwardly also. These movements free all parts of the core form from themodule.

The two exterior fonns E and E are rigid and of L- shape, each embracingone side wall and one end wall of the module. In stripping, these twoforms move away from each other in diagonal directions as indicated bythe arrows 11. The module is then free to be lifted vertically out ofthe forms and transported to the building site.

Referring now to FIGS. 1 and 3, the core C has a continuous peripheralsheet metal skin 15 extending around the four sides of the core. Avertical gusset plate 16 is welded to the skin 15 at the middle of eachside and at spaced intervals additional vertical gusset plates 17 arewelded to the skin. The interior edges of gussets 17 have flanges 18 andthe interior edges of the middle gussets 16 have flanges 19.

The flanges 19 of middle gussets 16 are welded to a plurality ofhorizontal walers 20 whereas the flanges 18 of the other gussets 17 arenot connected to the walers. The opposite ends'of each waler 20 areequipped with slotted wedge brackets 21 to receive vertical wedges 22.The middle of each waler 20 is secured to a vertical beam 24.

The core is expanded and contracted by a vertically movable corestripping frame 25. Frame 25 has a plurality of longitudinal horizontalmembers 26 and a plurality of transverse horizontal members 27 disposedin the center of the core midway between the walers 20 on the oppositesides. The ends of longitudinal members 26 are welded to a pair ofvertical tubes 28 and the ends of transverse members 27 are welded to apair of vertical tubes 29. The tubes 28 are slidable on a pair ofcylindrical vertical guides 30 which are mounted on a pallet frame 31.Pallet frame 31 supports core stripping frame 25 and the entire core C.

Core stripping frame 25 is raised and lowered on guides 30 by a pair ofscrew jacks 35 as shown in FIG. 3. Each jack 35 is mounted on a supporttube 36 on pallet frame 31. The jackscrews are connected at 37 with thelower beam 26 of frame 25. The jackscrews are raised and lowered by nutswhich are rotated by shafts 38 from a gear box 40 by means of a handcrank 41.

Gear box 40 is mounted on a support 42 on pallet frame 31.

Each tube 28 and 29 is equipped with upper and lower vertical cam plates45, each having an inclined cam slot 46. Each vertical beam 24 isequipped with brackets 47 carrying cam follower rollers 48 disposed inthe cam slots 46. When frame 25 is in lower position as shown in FIG. 3,rollers 48 are disposed in the upper ends of cam slots 46 causing thecore to be expanded to operative position. In order to preventdeflection of vertical beams 24, these beams and the tubes 28 and 29 areequipped at mid height with opposed slotted wedge brackets 49 to receivewedges 50. These wedges are approximately on the same level as theintermediate horizontal members 26 and 27 of frame 25. Walers 20 bearagainst flanges 18 of gussets 17 as shown in FIG. 1 to preventdeflection of core skin from the fluid pressure of the concrete when theconcrete is poured into the form.

In order to contract the core for stripping, the wedges 22 and 50 areremoved and the stripping frame 25 is raised by rotation of the crankhandle 41 which operates the jackscrews 35. Upward movement of frame 25in the direction of arrow 51 in FIG. 3 moves the cam slots 46 upwardrelative to cam follower rollers 48 pulling all four vertical beams 24inward in the direction of arrows 10. The horizontal walers beingconnected with the beams 24 are moved inward with the beams. The walers20 being connected to the middle vertical gussets 16 thereby pull thecore skin 15 inward at the mid point of each side of the core asillustrated in FIG. 7.

Since the other gussets 17 are not connected with the walers, the walersleave contact with these gussets as the core skin is bowed inwardly. Theinward deflection of the core skin 15 in this manner not only pulls theskin away from the four sides of the module M but also pulls the cornersinwardly away from contact with the module whereby the module isentirely freed from contact with the core for stripping.

Each L-shaped exterior form E, and E has an interior sheet metal skin 55at a distance from the core skin 15 to form a pouring space S forreceiving concrete to form the module M. The skin 55 is rigiditied byvertical gusset plates 56 which are welded to the skin and also securedto horizontal walers 60 at mid height. Each exterior form E, and E is arigid structure supported on trolleys for movement away from the modulein stripping as explained in connection with FIG. 7.

Thus, the form E, is mounted on three wheels 61 which roll on threeparallel tracks 62 as shown in FIG. 1. Each track is equipped with astop 63 at its outer end to limit the retracting movement. Similarly,the form E is mounted on three wheels 65 which roll on three paralleltracks 66. Each form carries one end wall and one side wall of the form.

As shown in FIG. 6, the two meeting comers of the exterior forms aresecured together by horizontal swing bolts 70 which are pivotallymounted at 71 on one form and swing into a notched bracket 72 on theother form for securement by a wing nut 73. The vertical joint betweenthe comers of the forms is closed by a resilient seal strip 74.

Along the four sides of the forms, the space S is closed at the bottomby plate 75 mounted on the upper flanges of l-beams 76 in the palletframe 31 as shown in FIG. 5. Core skin 15 and exterior form skin 55 abutopposite edges of this plate, the joints being sealed by resilient sealstrips 77. The lower edge of core skin 15 is reinforced by a plate 78which bears at intervals against the heads of adjustable bolts 79 in aflange of bottom waler 20. The lower edges of exterior forms E, and E,are clamped by a series of swing bolts 80. Each swing bolt 80 ispivotally connected at 81 to l-beam 76 to swing into a slotted bracket82 on the bottom of the exterior form and be secured by a wing nut 83.

To facilitate pouring concrete into the space S, a removable slopingapron 85 is provided as shown in FIGS. 1 and 4. This apron extendsaround all four sides of the form above the core structure. it has anopen center, rectangular frame 86 with depending ears 87 having notchesat 88 to rest on the upper edges of horizontal plate 89 mounted on theinside of core skin 15.

At the center of each short side and center of each long side, the apron85 is equipped with a horizontal stay belt 90 welded to frame 86. Whenapron 85 is lowered into place, each bolt 90 enters a slot 91 in abracket 92 on the upper edge of the exterior form and is secured inposition by wing nut 93. Lock nuts 94 provide adjustment to control thewidth of space S. When concrete is poured into the space S, the ears 87and nuts 93 provide abutments to prevent the core and exterior formsfrom deflecting away from each other under the fluid pressure of theconcrete. Preparatory to stripping, wing nuts 93 are loosened and apron85 is lifted out of the way.

Window and door openings are provided where desired in the module byinserting rectangular frames (not shown) into the pour space S as iswell understood in the art.

Having now described my invention and in what manner the same may beused, what I claim as new and desire to protect by Letters Patent is:

l. A form for casting portable concrete building modules having fourintegral room size walls, comprising a contractible rectangular corewhose walls correspond in size to said room size walls, a pair ofL-shaped exterior forms having the same height as the core which closetogether in a rectangle spaced about the core to define with the core afour-sided vertical cavity, releasable means connecting the ends of oneof said exterior forms to the ends of the other exterior form at twoopposite comers of the rectangle, said releasable means permittingcomplete separation of said two exterior forms from each other, trolleyssupporting said exterior forms for horizontal movement toward and awayfrom said core, and tracks below the four comers of the rectangle forsaid trolleys of both exterior forms extending approximately at rightangles to a diagonal vertical plane through said two opposite comers,whereby movement of said exterior forms along said tracks causes maximumand equal separation of the exterior forms from all four sides of thecontracted core and enables ready vertical removal of a cast module fromthe form cavity.

2. A form as defined in claim 1, wherein said releasable means comprisesa straight horizontal swing bolt pivotally mounted at one end to oneexterior fonn and swingable into and out of a notched bracket affixed tothe other exterior form and a wing nut on the other end of the boltserving to clamp and unclamp the exterior form at said bracket.

3. A form as defined in claim 1, including a rectangular, open centerpouring apron having downwardly outwardly sloping walls, meansdetachably supporting said apron on said core, horizontal stay boltsprojecting outward from the four sides of said apron, and means on saidexterior forms having detachable engagement with the outer ends of saidstay bolts to prevent outward deflection of said exterior forms.

4. A form as defined in claim 3, said last means comprising upstandingbrackets on said exterior forms having vertical slots to receive saidstay bolts.

5. A form as defined in claim 1, wherein during casting said four-sidedvertical cavity is closed at the bottom by a rectangular pallet frameformed of l-beams, there being four plates seated on the upper flangesof said I-beams against whose opposite edges abut lower portions of thewalls of said core and exterior forms, swing bolts each pivoted at oneend to the pallet frame and swingable into a notched bracket affixed toan exterior form, and wing nuts on the other ends of said swing boltsfor releasably clamping the exterior forms threaded into walers fixed toand within the core.

l l= l=

1. A form for casting portable concrete building modules having fourintegral room size walls, comprising a contractible rectangular corewhose walls correspond in size to said room size walls, a pair ofL-shaped exterior forms having the same height as the core which closetogether in a rectangle spaced about the core to define with the core afour-sided vertical cavity, releasable means connecting the ends of oneof said exterior forms to the ends of the other exterior form at twoopposite corners of the rectangle, said releasable means permittingcomplete separation of said two exterior forms from each other, trolleyssupporting said exterior forms for horizontal movement toward and awayfrom said core, and tracks below the four corners of the rectangle forsaid trolleys of both exterior forms extending approximately at rightangles to a diagonal vertical plane through said two opposite corners,whereby movement of said exterior forms along said tracks causes maximumand equal separation of the exterior forms from all four sides of thecontracted core and enables ready vertical removal of a cast module fromthe form cavity.
 2. A form as defined in claim 1, wherein saidreleasable means comprises a straight horizontal swing bolt pivotallymounted at one end to one exterior form and swingable into and out of anotched bracket affixed to the other exterior form and a wing nut on theother end of the bolt serving to clamp and unclamp the exterior form atsaid bracket.
 3. A form as defined in claim 1, including a rectangular,open center pouring apron having downwardly outwardly sloping walls,means detachably supporting said apron on said core, horizontal staybolts projecting outward from the four sides of said apron, and means onsaid exterior forms having detachable engagement with the outer ends ofsaid stay bolts to prevent outward deflection of said exterior forms. 4.A form as defined in claim 3, said last means comprising upstandingbrackets on said exterior forms having vertical slots to receive saidstay bolts.
 5. A form as defined in claim 1, wherein during casting saidfour-sided vertical cavity is closed at the bottom by a rectangularpallet frame formed of I-beams, there being four plates seated on theupper flanges of said I-beams against whose opposite edges abut lowerportions of the walls of said core and exterior forms, swing bolts eachpivoted at one end to the pallet frame and swingable into a notchedbracket affixed to an exterior form, and wing nuts on the other ends ofsaid swing bolts for releasably clamping the exterior forms to thepallet frame.
 6. A form as defined in claim 5, wherein the walls of saidcore in their bottom portions where they abut said plates seated on thepallet are reinforced by internal bracing plates, said bracing platesbeing adjustably pressed outwardly by the heads of bolts which arethreaded into walers fixed to and within the core.